Packaging assembly

ABSTRACT

The present invention relates to a packaging assembly comprising one or more primary packages and a secondary packaging and a method to assemble packaging. Each of the primary packages has a flexible packaging and comprises a plurality of compressed absorbent articles. The secondary packaging comprises a case comprising a front wall panel and a back wall panel, a first and a second side wall panel, a top opening and a bottom opening.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119 to India Patent Application Serial No. 202211002269, filed on Jan. 14, 2022, the entire disclosure of which is hereby incorporated by reference.

FIELD

The present disclosure relates to a packaging assembly for absorbent articles.

BACKGROUND

Rigid boxes are widely used to package all kinds of articles, inter alia for packaging and storing absorbent articles for personal hygiene, such as diapers, pants or feminine hygiene articles. Boxes containing absorbent articles are typically formed of cardboard. Typically, boxes contain e.g. two, three or more bundles of absorbent articles, such as diapers or pants, with each bundle being provided within a flexible packaging, such that the boxes contain several of such flexible packages, each filled with a number of absorbent articles. Typically, these absorbent articles are compressed within the flexible packaging to save space.

For storage and transport, the boxes are typically stacked and piled up on one another. To this end, the boxes have to be sufficiently stable to withstand deformation and, worst case, even collapse upon stacking. On the other hand, the material consumption for making the boxes, typically cardboard, or corrugated cardboard, is desirably reduced as much as possible due to cost and weight. There is also an environment cost associated with the use of such large quantities of cardboard. Additionally, due to the varying sizes of the flexible packages of compressed absorbent articles, rigid boxes usually allow for an empty space between the top panel and the flexible packages to not damage the packages and/or absorbent articles during storage and/or transport.

Given the ever present need to save environment and material costs, there is a need to provide a packaging system that affords the necessary protection to absorbent articles and a sufficient stability during storage and transport, but also delivers on savings, both in terms of material and space.

SUMMARY

The present invention provides a packaging assembly comprising one or more primary, flexible packages and a secondary packaging. n is the number of comprised primary, flexible packages and can be 1 or more. Each of the primary, flexible packages has a flexible packaging and comprises a plurality of compressed absorbent articles 10; i.e. the plurality of absorbent articles 10 are within the flexible packaging. Each primary, flexible package has a maximum height y_(Pn).

Accordingly each primary, flexible package has a maximum width x_(Pn), which is the distance of the point, which was nearest to the first side wall panel 202 of the case of secondary packaging, and the point, which was nearest to the second side wall panel 204 of the case of secondary packaging; and a maximum depth z_(Pn), which is the distance of the point, which was nearest to the front wall panel 201 of the case of secondary packaging, and the point, which was nearest to the back wall panel 203 of the case of secondary packaging. The primary, flexible packages have an average maximum height y_(P), which can be determined from the sum of the maximum heights y_(Pn) of all primary, flexible packages divided by the number n of primary, flexible packages. Accordingly, the average maximum width x_(P) and the average maximum depth z_(P) can be calculated from the sum of the maximum widths x_(Pn) divided by n and the sum of the maximum widths z_(Pn) divided by n.

The secondary packaging comprises a case comprising a front wall panel 201 and a back wall panel 203, a first 202 and a second side wall panel 204, a top opening 205 and a bottom opening 206. Top opening according to the invention means that at least 80%, preferably at least 90%, more preferably at least 95%, even more preferably at least 99% or even 100% of the top area of the case are not covered by secondary packaging material. Bottom opening according to the invention means that at least 80%, preferably at least 90%, more preferably at least 95%, even more preferably at least 99% or even 100% of the bottom area of the case are not covered by secondary packaging material. The case has a height y_(S) which corresponds to the height of each of the front wall panel 201, the back wall panel 203, the first 202 and the second side wall panel 204, i.e. these panels all have the same height; a width x_(S) corresponding the distance between the first 202 and the second side wall panel 204; and a depth z_(S), corresponding the distance between the front wall panel 201, the back wall panel 203.

The one or more primary, flexible packages are arranged within the secondary packaging such that the one or more primary, flexible packages form at least one layer when arranged next to each other from the first 202 to the second side wall panel 204 of the case. m_(x) is the number of these layers and is 1 or more. Further, the one or more primary, flexible packages form at least one layer when arranged on top of each other from bottom to top of the case. m_(y) is the number of these layers and is 1 or more.

Further, the one or more primary, flexible packages form at least one layer when arranged next to each other from the front wall panel 201 to the back wall panel 203 of the case. m_(z) is the number of these layers and is 1 or more.

According to the invention, the height of each primary, flexible packages is parallel to the height of the secondary packaging. The height of the secondary packaging y_(S) is 90% to 100% of m_(y)-times the height of the average maximum height y_(P) of the number n of primary, flexible packages.

The maximum height y_(Pn) is determined after disassembling the packaging assembly by measuring the distance of the point, which was nearest to the top opening 205 of the secondary packaging, and the point, which was nearest to the bottom opening 206 of the secondary packaging, of a primary, flexible package. The primary, flexible package is placed on a plane surface, without applying external pressure after disassembling the packaging assembly and subsequently allowing the primary, flexible package to recover for 8 hours at a temperature of 40° C. and pressure of 1 atm.

The invention further provides a method to assemble packaging comprising a first step of providing a number n of primary, flexible packages with n being 1 or more. Each primary, flexible package comprises a plurality of compressed absorbent articles. Each primary, flexible package has a maximum height y′_(Pn), a maximum width x′_(Pn) and a maximum depth z′_(Pn), which are determined prior to the number n of primary, flexible packages is arranged in a packaging assembly. For this each primary, flexible package is placed on a plane surface, without applying external pressure. The primary, flexible packages have an average maximum height—prior to arranging in a packaging assembly—y′_(P), which can be determined from the sum of the maximum heights y′_(Pn) of all primary, flexible packages divided by the number n of primary, flexible packages. Accordingly, the average maximum width x′_(P) and the average maximum depth z′_(P) can be calculated from the sum of the maximum widths x′_(Pn) divided by n, and the sum of the maximum widths z′_(Pn) divided by n.

In a second step the number n of primary, flexible packages is arranged within a secondary packaging comprising a case comprising a front wall panel 201 and a back wall panel 203, a first 202 and a second side wall panel 204, a top opening 205 and a bottom opening 206, and having a height y_(S), a width x_(S) and a depth z_(S). The number n of primary, flexible packages form a number of layers m_(x), with m_(x) being 1 or more, arranged next to each other from the first 202 to the second side wall panel 204 of the case. The number n of primary, flexible packages also form a number of layers m_(y), with m_(y) being 1 or more, arranged on top of each other from bottom to top of the case, and a number of layers m_(z), with m_(z) being 1 or more, arranged next to each other from the front 201 to the back wall panel 203 of the case.

In an optional third step, the arranged primary, flexible packages are compressed such that the height of m_(y)-times the height of the average maximum height y′_(P) of the number n of primary, flexible packages is reduced.

Due to the inventive packaging assembly and method to assemble packaging a sufficient stability during storage and transport can be maintained while saving material and reducing the required space in comparison to conventional boxes, in particular when stacking two or more packaging assemblies on top of each other.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an example absorbent article in the form of a taped diaper, garment-facing surface facing the viewer, in a flat laid-out state;

FIG. 2 is a plan view of an example absorbent article that is a sanitary napkin;

FIG. 3 is a view of an example primary, flexible packages comprising a plurality of folded absorbent articles;

FIG. 4 a is a plan view of a disassembled case of the secondary packaging, in a flat laid-out state;

FIG. 4 b is a top and side elevation view of an example secondary packaging of the present disclosure;

FIG. 5 a is a top and side elevation view of an example packaging assembly of the present disclosure;

FIG. 5 b is a top and side elevation view of an example packaging assembly of the present disclosure; and

FIG. 6 is a top and side elevation view of an example packaging assembly of the present disclosure.

DETAILED DESCRIPTION

“Absorbent article” refers to devices that absorb and contain body exudates, particularly urine and other water-containing liquids, and, more specifically, refers to devices that are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. Absorbent articles may include diapers (for babies and infants as well as for adult incontinence), pants (for babies and infants as well as for adult incontinence). As used herein, the term “exudates” includes, but is not limited to, urine, blood, vaginal discharges, sweat and fecal matter. Preferred absorbent articles of the present invention are disposable absorbent articles, more preferably disposable diapers, disposable pants and disposable absorbent inserts.

“Diaper” and “pant” refers to an absorbent article generally worn by babies, infants and incontinent persons about the lower torso so as to encircle the waist and legs of the wearer and that is specifically adapted to receive and contain urinary and fecal waste. In a pant, as used herein, the longitudinal edges of the first and second waist region are attached to each other to a pre-form waist opening and leg openings. A pant is placed in position on the wearer by inserting the wearer's legs into the leg openings and sliding the pant absorbent article into position about the wearer's lower torso. A pant may be pre-formed by any suitable technique including, but not limited to, joining together portions of the absorbent article using refastenable and/or non-refastenable bonds (e.g., seam, weld, adhesive, cohesive bond, fastener, etc.). A pant may be pre-formed anywhere along the circumference of the article (e.g., side fastened, front waist fastened). In a diaper, the waist opening and leg openings are only formed when the diaper is applied onto a wearer by (releasable) attaching the longitudinal edges of the first and second waist region to each other on both sides by a suitable fastening system.

“Film” means a skin-like or membrane-like layer of material formed of one or more polymers, which does not have a form consisting predominately of a web-like structure of consolidated polymer fibers and/or other fibers.

“Flexible packaging” means any a skin-like or membrane-like layer of material. Examples for materials used in flexible packaging are one or more polymers, wood-based materials, e.g. specially treated, coated and/or blended paper; and web-like structure of consolidated polymer fibers and/or other fibers.

An example absorbent article 10 according to the present disclosure, shown in the form of a diaper, is represented in FIG. 1 . FIG. 1 is a plan view of the example absorbent article 10, garment-facing surface facing the viewer in a flat, laid-out state (i.e., no elastic contraction). A further example absorbent article 10 according to the present disclosure, shown in the form of a sanitary napkin, is represented in FIG. 2 . The absorbent articles 10 of FIGS. 1 and 2 are shown for illustration purposes only as the present disclosure may be used for a wide variety of diapers, pants, or other absorbent articles, such as sanitary napkins and absorbent pads, for example.

The absorbent article 10 may comprise a front waist region, a crotch region, and a back waist region. The crotch region may extend intermediate the front waist region and the back waist region. The front wait region, the crotch region, and the back waist region may each be ⅓ of the length of the absorbent article 10. The absorbent article 10 may comprise a front end edge 18, a back end edge 20 opposite to the front end edge 18, and longitudinally extending, transversely opposed side edges 22 and 24 defined by the chassis 52.

The absorbent article 10 may comprise a liquid permeable topsheet, a liquid impermeable backsheet, and an absorbent core positioned at least partially intermediate the topsheet and the backsheet. The absorbent article 10 may also comprise one or more pairs of barrier leg cuffs with or without elastics, one or more pairs of leg elastics, one or more elastic waistbands, and/or one or more acquisition materials. The acquisition material or materials may be positioned intermediate the topsheet and the absorbent core. An outer cover material, such as a nonwoven material, may cover a garment-facing side of the backsheet. The absorbent article 10 may comprise back ears in the back waist region. The back ears may comprise fasteners and may extend from the back waist region of the absorbent article 10 and attach (using the fasteners) to the landing zone area or landing zone material on a garment-facing portion of the front waist region of the absorbent article. The absorbent article 10 may also have front ears in the front waist region. The absorbent article 10 may have a central lateral (or transverse) axis 12 and a central longitudinal axis 11. The central lateral axis 12 extends perpendicular to the central longitudinal axis 11. The central longitudinal axis 11 may extend from a midpoint of the front end edge 18 to a midpoint of the back end edge 20.

A packaging assembly is provided. The packaging assembly comprises one or more primary, flexible packages and a secondary packaging. n is the number of comprised primary, flexible packages and can be 1 or more. In particular, n may be 2 or more, 4 or more, 6 or more, or even 9 or more. When n is 2 or more, it is desirable for m_(y) to be 2 or more, so to have two rows in height. Each primary, flexible package comprises a plurality of compressed absorbent articles 10, which may be folded along the central lateral axis 12. Preferably, the absorbent articles are diapers and are folded along or parallel to the central lateral axis 12. FIG. 3 shows an exemplary primary, flexible package with the absorbent articles 10, diapers in the example shown, being folded along the central lateral axis 12 and arranged in parallel and in two rows in the longitudinal direction of the absorbent articles 10. The primary, flexible package in FIG. 3 comprises a grip, or, more preferably, a handle 31. The grip 31 can be an opening or slit enabling to grip the primary, flexible package. The absorbent articles 10 are packed under compression so as to reduce the size of the primary, flexible packages, while still providing an adequate amount of absorbent articles per package. By packaging the absorbent articles under compression, caregivers can easily handle and store the primary, flexible packages, while also providing distribution savings to manufacturers and reducing used shelf space owing to the size of the primary, flexible packages. Due to the flexible packaging, the primary packages can be further compressed before, during or after being arranged within the packaging assembly.

Due to deviations in compression levels and/or arrangement within primary, flexible packages of the absorbent articles, the primary, flexible packages may vary, at least slightly, in size, i.e. in maximum height y_(Pn), in maximum width x_(Pn) and/or in maximum depth z_(Pn). Thus, the average maximum height y_(P), the average maximum width x_(P) and the average maximum depth z_(P) over all primary, flexible packages within the secondary packaging are determined. The primary, flexible packages within the assembly may be chosen such that the height of the primary, flexible package with the largest maximum height is maximal 120%, preferably maximal 115%, more preferably maximal 110% or even maximal 105% of the height of the primary, flexible package with the smallest maximum height. The primary, flexible packages within the assembly may be chosen such that the width of the primary, flexible package with the largest maximum width is maximal 120%, preferably maximal 115%, more preferably maximal 110% or even maximal 105% of the width of the primary, flexible package with the smallest maximum width. The primary, flexible packages within the assembly may be chosen such that the depth of the primary, flexible package with the largest maximum depth is maximal 120%, preferably maximal 115%, more preferably maximal 110% or even maximal 105% of the depth of the primary, flexible package with the smallest maximum depth. The primary, flexible packages within the assembly may be chosen such that the maximum height is maximal 120%, preferably maximal 115%, more preferably maximal 110% or even maximal 105% of the minimum height of the same primary, flexible package. Accordingly, the primary, flexible packages within the assembly may be chosen such that the maximum width is maximal 120%, preferably maximal 115%, more preferably maximal 110% or even maximal 105% of the minimum width of the same primary, flexible package. Accordingly, the primary, flexible packages within the assembly may be chosen such that the maximum depth is maximal 120%, preferably maximal 115%, more preferably maximal 110% or even maximal 105% of the minimum depth of the same primary, flexible package.

The width of the secondary packaging, shown in FIG. 4 a in a flat laid-out state and assembled in FIG. 4 b , is chosen to be at least m_(x) times the average maximum width x_(P) of the primary, flexible packages, typically the distance between the inner sides of the first 202 and the second side wall panel 204 of the secondary package equals m_(x) times the average maximum width x_(P). Accordingly, the depth of the secondary packaging is chosen to be at least m_(z) times the average maximum depth z_(P) of the number n of primary, flexible packages. Typically, the distance between the inner sides of the front wall panel 201 and the back wall panel 203 of the secondary package equals m_(z) times the average maximum depth z_(P).

To facilitate assembling, the case of the secondary packaging may comprise at least one flap 207 as extension to any of the first 202, the second side wall panel 204, the front wall panel 201 or the back wall panel 203, which may be attached, e.g. by adhesive means, to a neighboring wall panel. In FIG. 4 a , the secondary packaging exemplarily comprises a flap 207 as extension to the second side wall panel 204, which may be attached the to the front wall panel 201. As anticipated by the person skilled in the art, any attachment means known from assembling boxes, cases or other containers, which can be made of cardboard or similar rigid materials, can be employed. Additionally, any two of the neighboring wall panels may be joined to each other by the attachment means to arrive at the case of the secondary packaging as shown in FIG. 4 b , i.e. the front wall panel 201 to the second side wall panel 204 or vice versa, the front wall panel 201 to the first side wall panel 202 or vice versa, the back wall panel 203 to the second side wall panel 204 or vice versa, the back wall panel 203 to the first side wall panel 202 or vice versa.

The height of the secondary packaging y_(S) is chosen to be 90% to 100%, preferably 91% to 99%, more preferably 92% to 98%, even more preferably 93% to 97%, in particular 94% to 96% or even 95% of m_(y)-times the height of the average maximum height y_(P) of the number n of primary, flexible packages. Due to the smaller or equal height of the secondary packaging in comparison to the height of the one or more primary, flexible packages stacked on top of each other, the primary, flexible packages can be further compressed in height. In particular, when two or more packaging assemblies are stacked on top of each other such that the top opening area of one secondary packaging may to at least 90%, preferably to at least 95%, more preferably to at least 99% or even to 100% covered by the bottom opening area of the neighboring secondary packaging; the primary, flexible packages of the packaging assembly on the bottom are further compressed due to the weight of the packaging assembly on top. This compression in a stack might lead to the arranged rows of primary, flexible packages having the same height as the secondary packaging in an assembly, thus reducing the overall height of the stack by up to 10% and thus saving space during warehousing and/or transportation.

When two or more packaging assemblies are stacked on top of each other as described, then one or more panels of the front wall panel 201, the back wall panel 203, the first 202 and the second side wall panel 204 of the secondary packaging on the top may rest on the corresponding one or more panels of the packaging assembly on the bottom, thus providing similar or even better stability than a stack made of completely closed cardboard boxes. Preferably, within the stack, the front wall panel 201 of one inventive packaging assembly rests on top of the front wall panel 201 of another inventive packaging assembly; the back wall panel 203 of one inventive packaging assembly rests on top of the back wall panel 203 of another inventive packaging assembly; the first side wall panel 202 of one inventive packaging assembly rests on top of the first side wall panel 202 of another inventive packaging assembly; and the second side wall panel 204 of one inventive packaging assembly rests on top of the second side wall panel 204 of another inventive packaging assembly.

Further, the packaging assembly according to the invention provides more stability in a stack than a packaging assembly, for which the secondary packaging is chosen to be larger in height than the rows of primary, flexible packages. While one would expect such a non-inventive assembly to be more stable due to the direct contact of the rigid cardboard wall panels, this has been found to be not applicable. In such a non-inventive assemble, even if the neighboring assemblies within a stack are aligned to sit exactly on top of each other, i.e. the rigid, for example cardboard, wall panels sit on top of each other to provide stability, there is an empty space formed between adjacent primary, flexible packages within a stack. There are different disadvantages associated with that: there is less contact area between the neighboring assemblies and thus shifts within the stack due to external forces, in particular during transport, are more likely to lead to the stack collapsing. In particular, the wall panels and edges of the secondary packaging may be shifted in such a way that they fall into the formed empty spaces leading to the stack collapsing. Secondly, one or more wall panels may lose stability due to damages, which may be mechanical or, in particular if the wall panels are paper based, due to soaking with humidity or water. In such a scenario, a stack of non-inventive assemblies would collapse in the direction of the destabilized wall panel or wall panels, most likely even if only one packaging assembly is affected. Due to relation in the inventive packaging assembly that the height of the secondary packages y_(S) is 90 to 100%, preferably 91% to 99%, more preferably 92% to 98%, even more preferably 93% to 97%, in particular 94% to 96% or even 95% of the height of the rows of flexible, primary packages (m_(y) times y_(P)), primary, flexible packages are in direct contact with adjacent primary packages within a stack. As a consequence, neighboring assemblies in a stack do not have to be aligned to exactly sit on top of the neighboring assembly, i.e. the top 205 with the bottom opening 206 or the bottom 206 with the top opening 205 of neighboring assemblies do not have to be completely matched, to not collapse due to the compressed primary, flexible packages providing stability. Due to the friction between adjacent primary flexible packages and missing empty spaces, also shifts within the stack due to external forces during transport and the described damages to parts of the stack can be reduced. In addition, the height relation between the rows of flexible, primary packages and the secondary packaging is chosen in such a way that the wall panels of neighboring assemblies typically sit on top of each other within a stack due to the compression caused by the weight of the assemblies on top of the stack, further stabilizing the stack.

Typically, primary, flexible packages may be aligned within the secondary packaging to form 1 to 4 rows in each direction, thus m_(y) is 1 to 4, m_(x) is 1 to 4 and m_(z) is 1 to 4. Exemplarily, 8 primary, flexible packages may be aligned within the secondary packaging to form 2 rows in each direction, thus m_(y) is 2, m_(x) is 2 and m_(z) is 2. Alternatively, 8 primary, flexible packages may be aligned within the secondary packaging to form 2 rows in height, 1 in width and 4 in depth, thus m_(y) is 2, m_(x) is 1 and m_(z) is 4. Further, 8 primary, flexible packages may be aligned within the secondary packaging to form 1 row in height, 4 rows in width and 2 in depth, thus m_(y) is 1, m_(x) is 4 and m_(z) is 2.

The secondary packaging comprises a case comprising a front wall panel 201 and a back wall panel 203, a first 202 and a second side wall panel 204, a top opening 205 and a bottom opening 206. The material of the case of the secondary packaging is chosen to provide sufficient rigidity and thus stability. Preferably the front wall panel 201, the back wall panel 203, the first and the second side wall panel 202, 204 comprise cardboard and/or corrugated cardboard. The front wall panel 201, the back wall panel 203, the first and the second side wall panel 202, 204 may consist of cardboard and/or corrugated cardboard. Cardboard and/or corrugated cardboard are materials that are light but still provide sufficient stability. In particular, when two or more packaging assemblies are stacked on top of each other and one or more panels of the front wall panel 201, the back wall panel 203, the first 202 and the second side wall panel 204 of the secondary packaging on the bottom rest on the corresponding one or more panels of the packaging assembly on top as described before, cardboard and/or corrugated cardboard provides a stability to the whole stack comparable to a whole cardboard and/or corrugated cardboard box, but reduces the required space. In addition, the cardboard and/or corrugated cardboard may be printed with graphics and/or texts.

The secondary packaging may comprise exactly one case or even consist of one case.

The secondary packaging may be of generally rectangular shape, preferably the first 202 and the second side wall panel 204 have the same size and shape and the front wall panel 201 and the back wall panel 203 may have the same size and shape. The front wall panel 201, the back wall panel 203, the first and the second side wall panel 202, 204 may all have the same size and shape.

The packaging assembly may further comprise at least one tertiary flexible packaging 301, which covers at least partially the top opening 205 and/or the bottom opening 206 of the secondary packaging, preferably the at least one tertiary flexible packaging 301 covers the top opening 205 or the bottom opening 206 completely, even more preferably the at least one tertiary flexible packaging 301 the top opening 205 and the bottom opening 206 completely as shown in FIG. 6 . The tertiary flexible packaging 301 provides protection against damaging of the primary, flexible packages. In addition, due to the at least one tertiary flexible packaging 301 the primary packages may be kept in position within the secondary packaging also when the packaging assembly is lifted and/or moved without support of a pallet or the like.

In addition, the at least one tertiary flexible packaging 301 may cover at least partially, preferably completely, two or more of the panels selected from the front wall panel 201, the back wall panel 203, the first and the second side wall panel 202, 204 of the secondary packaging. Preferably, the at least one tertiary flexible packaging 301 may cover at least partially, preferably completely, two or more of the panels selected from the front wall panel 201, the back wall panel 203, the first and the second side wall panel 202, 204 of the secondary packaging. The at least one tertiary flexible packaging 301 thus provides protection against damaging of the secondary packaging. Preferably, the at least one tertiary flexible packaging 301 partially, preferably completely, covers the top opening 205, the bottom opening 206, the front wall panel 201, the back wall panel 203, the first and the second side wall panel 202, 204 of the secondary packaging as shown in FIG. 6 . Due to such an at least one tertiary flexible packaging 301 the primary packages may be kept in position within the secondary packaging also when the packaging assembly is lifted and/or moved and both the primary, flexible packages and the secondary packaging are protected against damages.

Alternatively, the at least one tertiary flexible packaging 301 may cover at least partially, the top opening and the bottom opening of a stack of two or more secondary packaging arranged on top of each other in such a way that the top opening area of one secondary packaging is to at least 90%, preferably to at least 95%, more preferably to at least 99% or even to 100% covered by the bottom opening area of the neighboring secondary packaging.

Preferably, the at least one tertiary flexible packaging 301 is a film. Thus, the primary, flexible packages and the secondary packaging are additionally protected against water or humidity damages. The at least one tertiary flexible packaging 301 may further be a transparent film, so that the graphics and/or texts of the primary, flexible packages and the secondary packaging can be viewed also when arranged within the packaging assembly.

In the packaging assembly disclosed, the one or more primary, flexible packages may be arranged within the secondary packaging such that the front end edge 18 of each compressed absorbent article 10 points to the top opening 205 or the bottom opening 206. The front end edges 18 thus may all point towards the top opening 205, all point towards the bottom opening 206 or some may point towards the top opening 205, while others point towards the bottom opening 206. In the latter case, the front end edges 18 of the absorbent articles 10 desirably alternatingly point to the top opening 205 and the bottom opening 206, i.e. the front end edges 18 of neighboring absorbent article 10 point in opposite directions. In such an alignment, the compressed absorbent articles 10 may be arranged in parallel, thus the backsheets of the compressed absorbent articles 10 are parallel, and may be parallel to the front wall panel 201 and the back wall panel 203 of the secondary packaging; or may be parallel to the first side wall panel 202 and the second side wall panel 204.

Alternatively, in the packaging assembly disclosed, the one or more primary, flexible packages may be arranged within the secondary packaging such that the first side edge 22 of each compressed absorbent article 10 points to the top opening 205 or the bottom opening 206. The first side edges 22 thus may all point towards the top opening 205, all point towards the bottom opening 206 or some may point towards the top opening 205, while others point towards the bottom opening 206. In the latter case, the first side edges 22 of the absorbent articles 10 desirably alternatingly point to the top opening 205 and the bottom opening 206, i.e. the first side edges 22 of neighboring absorbent article 10 point in opposite directions. In such an alignment, the compressed absorbent articles 10 may be arranged in parallel, thus the backsheets of the compressed absorbent articles 10 are parallel, and may be parallel to the front wall panel 201 and the back wall panel 203 of the secondary packaging; or may be parallel to the first side wall panel 202 and the second side wall panel 204.

In both alternatives, the achievable compression level of the primary, flexible packages within the packaging assemble is maximized. In addition, the area per absorbent article 10, which is exposed to harming conditions, such as sun or humidity, outside the packaging assembly is minimized.

In both alternatives, the compressed absorbent articles 10 may be folded along or parallel to the central lateral axis 12. In particular, compressed absorbent articles 10 may be folded along or parallel to the central lateral axis 12 such that the backsheet faces outwards. The compressed absorbent articles 10 may be folded along the central lateral axis 12 and the one or more primary, flexible packages may be arranged within the secondary packaging such that the front end edge 18 and the back end edge 20 point to the top opening 205 or the bottom opening 206 of the secondary packaging, as shown in FIG. 5 a . Preferably, the compressed, absorbent articles in such a packaging assembly are diapers and/or pants. For this configuration, the maximum height of the primary, flexible packages typically varies the most within a given stack of absorbent articles due to the waist bands of diapers and/or pants, which might vary in height due to their flexibility. In the example shown in FIG. 5 a , there are 4 primary packages arranged in such a way that m_(y) is 1, m_(x) is 2 and m_(z) is 2. According to the invention, the height of the secondary packaging y_(S) would thus be 90 to 100% of the average maximum height y_(P) of the primary, flexible packages.

The compressed absorbent articles 10 may be folded along the central lateral axis 12 and the one or more primary, flexible packages may be arranged within the secondary packaging such that the first side edge 22 and the second side edge 24 point to the top opening 205 point to the top opening 205 or the bottom opening 206 of the secondary packaging, as shown in FIG. 5 b . In such a packaging assembly, it is desirable that the first side edges 22 may all point towards the top opening 205, all point towards the bottom opening 206 or some may point towards the top opening 205, while others point towards the bottom opening 206. In the latter case, the first side edge 22 of the absorbent articles 10 desirably alternatingly point to the top opening 205 and the bottom opening 206, i.e. the first side edges 22 of neighboring absorbent article 10 point in opposite directions. Preferably, the compressed, absorbent articles in such a packaging assembly are diapers and/or pants. In the example shown in FIG. 5 b , there are 4 primary packages arranged in such a way that m_(y) is 2, m_(x) is 1 and m_(z) is 2. According to the invention, the height of the secondary packaging y_(S) would thus be 90 to 100% of two times the average maximum height y_(P) of the primary, flexible packages.

In the disclosed packaging assembly, each primary, flexible package may comprise at least one handle or grip 31 and is arranged such that at least one part of the at least one handle or grip 31 faces the top opening and can be gripped through the top opening 205 of the secondary packaging, as shown in FIG. 5 b . Hence, the disassembly of the packaging assembly is facilitated. Each primary, flexible package may comprise exactly one handle or grip 31. The complete one handle or grip 31 may face the top opening and may be gripped through the top opening 205 of the secondary packaging.

A stack of two or more packaging assemblies according to the invention is additionally disclosed. Within the stack two or more packaging are aligned on top of each other in such a way that the top opening 205 area of one assembly is to at least 90%, preferably to at least 95%, more preferably to at least 99% or even to 100% covered by the bottom opening 206 area of the neighboring assembly. The two or more packaging assemblies may preferably be aligned on top of each other in such a way that each front wall panel 201, and thus each back wall panel 203, of each assembly faces the same direction. In addition, each first and thus each second side wall panel 202, 204 of each assembly faces the same direction. As a consequence, the overall height and thus consumed space of the disclosed stack may be lower than the sum of the heights of each packaging assembly.

Disclosed is also a method to assemble packaging comprising the steps of

-   1) providing a number n of primary, flexible packages with n being 1     or more,     -   wherein each primary, flexible package comprises a plurality of         compressed absorbent articles,     -   each primary, flexible package has a maximum height y′_(Pn), a         maximum width x′_(Pn) and a maximum depth z′_(Pn) determined         before arranging in a packaging assembly,     -   and wherein the number n of primary, flexible packages has an         average maximum height y′_(P), an average maximum width x′_(P)         and an average maximum depth z′_(P) determined before arranging         in a packaging assembly; -   2) arranging the number n of primary, flexible packages within a     secondary packaging comprising     -   a case comprising         -   a front wall panel (201) and a back wall panel (203),         -   a first and a second side wall panel, (202, 204),         -   a top opening (205) and a bottom opening (206),             and having a height y_(S), an inner width x_(S) and an inner             depth z_(S);             to form a number of layers m_(x), with m_(x) being 1 or             more, arranged next to each other from the first (202) to             the second side wall panel (204) of the case,             to form a number of layers m_(y), with m_(y) being 1 or             more, arranged on top of each other from the bottom to top             of the case, and to form a number of layers m_(z), with             m_(z) being 1 or more, arranged next to each other from the             front (201) to the back wall panel (203) of the case;

such that the height of each primary, flexible packages is parallel to the height of the secondary packaging and the height of the secondary packaging y_(S) is 90% to 100% of m_(y)-times the height of the average maximum height y′_(P) of the number n of primary, flexible packages.

Optionally the method further comprises the step of compressing the arranged primary, flexible packages such that the height of m_(y)-times the height of the average maximum height y′_(P) of the number n of primary, flexible packages is reduced.

In a preferred method according to the invention, two or more packaging assemblies are arranged, i.e. stacked, on top of each other in such a way that the top opening area of one secondary packaging is to at least 90%, preferably to at least 95%, more preferably to at least 99% or even to 100% covered by the bottom opening area of the neighboring secondary packaging. By stacking two or more packaging assemblies on top of each other, the described optional step of compression can be achieved, i.e. the primary, flexible packages are compressed in height such that the height of m_(y)-times the height of the average maximum height y′_(P) of the number n of primary, flexible packages is reduced. Due to the height difference within the packaging assembly, the overall height of the stack may be reduced by up to 10% in comparison to an isolated packaging assembly.

A further optional step of the method is applying at least one tertiary flexible packaging 301 covering at least partially, preferably completely, two or more of the panels selected from the front wall panel 201, the back wall panel 203, the first and the second side wall panel 202, 204 of the secondary packaging. The at least one tertiary flexible packaging 301 may be additionally applied such that it covers at least partially the top opening 205 and/or the bottom opening 206 of the secondary packaging. The at least one tertiary flexible packaging 301 may be chosen to be a film.

Within the inventive method, the secondary packaging may be chosen to be of generally rectangular shape, in particular the front wall panel 201 and the back wall panel 203 and/or the first and the second side wall panel 202, 204 of the at least one case have the same size and shape and additionally may comprise cardboard and/or corrugated cardboard.

The inventive method may further comprise the step of arranging the at least one primary, flexible package within the secondary packaging such that such that the front end edge 18 of each compressed absorbent article 10 points to the top opening 205 or the bottom opening 206. The front end edges 18 thus may all point towards the top opening 205, all point towards the bottom opening 206 or some may point towards the top opening 205, while others point towards the bottom opening 206. In the latter case, the front end edges 18 of the absorbent articles 10 desirably alternatingly point to the top opening 205 and the bottom opening 206, i.e. the front end edges 18 of neighboring absorbent article 10 point in opposite directions. In such an alignment, the compressed absorbent articles 10 may be arranged in parallel, thus the backsheets of the compressed absorbent articles 10 are parallel, and may be parallel to the front wall panel 201 and the back wall panel 203 of the secondary packaging; or may be parallel to the first side wall panel 202 and the second side wall panel 204.

Alternatively, in the method to assemble packaging disclosed, the one or more primary, flexible packages may be arranged within the secondary packaging such that the first side edge 22 of each compressed absorbent article 10 points to the top opening 205 or the bottom opening 206. The first side edges 22 thus may all point towards the top opening 205, all point towards the bottom opening 206 or some may point towards the top opening 205, while others point towards the bottom opening 206. In the latter case, the first side edges 22 of the absorbent articles 10 desirably alternatingly point to the top opening 205 and the bottom opening 206, i.e. the first side edges 22 of neighboring absorbent article 10 point in opposite directions. In such an alignment, the compressed absorbent articles 10 may be arranged in parallel, thus the backsheets of the compressed absorbent articles 10 are parallel, and may be parallel to the front wall panel 201 and the back wall panel 203 of the secondary packaging; or may be parallel to the first side wall panel 202 and the second side wall panel 204. In both alternatives, the achievable compression level of the primary, flexible packages within the packaging assemble is maximized. In addition, the area per absorbent article 10, which is exposed to harming conditions, such as sun or humidity, outside the packaging assembly is minimized.

In both alternatives, the compressed absorbent articles 10 may be folded along or parallel to the central lateral axis 12. In particular, compressed absorbent articles 10 may be folded along or parallel to the central lateral axis 12 such that the backsheet faces outwards. The compressed absorbent articles 10 may be folded along the central lateral axis 12 and the one or more primary, flexible packages may be arranged within the secondary packaging such that the front end edge 18 and the back end edge 20 point to the top opening 205 or the bottom opening 206 of the secondary packaging.

The compressed absorbent articles 10 may be folded along the central lateral axis 12 and the one or more primary, flexible packages may be arranged within the secondary packaging such that the first side edge 22 and the second side edge 24 point to the top opening 205 point to the top opening 205 or the bottom opening 206 of the secondary packaging.

In the disclosed method, each primary, flexible package may be provided to comprise at least one handle or grip 31 and is arranged such that at least one part of the at least one handle or grip 31 faces the top opening and can be gripped through the top opening 205 of the secondary packaging. Thus, the disassembly of the packaging assembly is facilitated. Each primary, flexible package may comprise exactly one handle or grip 31. The complete one handle or grip 31 may face the top opening and may be gripped through the top opening 205 of the secondary packaging.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such embodiment. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the present disclosure. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this disclosure. 

What is claimed is:
 1. A packaging assembly comprising: a number n of primary, flexible packages with n being 1 or more, wherein each primary, flexible package comprises a plurality of compressed absorbent articles (10), each primary, flexible package has a maximum height y_(Pn), a maximum width x_(Pn) and a maximum depth z_(Pn), and wherein the number n of primary, flexible packages has an average maximum height y_(P), an average maximum width x_(P) and an average maximum depth z_(P); and a secondary packaging, wherein the secondary packaging comprises a case comprising: a front wall panel (201) and a back wall panel (203), a first and a second side wall panel (202, 204), a top opening (205) and a bottom opening (206), and having a height y_(S), a width x_(S) and a depth z_(S); wherein the number n of primary, flexible packages is arranged within the secondary packaging such that the number n of primary, flexible packages: form a number of layers m_(x), with m_(x) being 1 or more, arranged next to each other from the first side wall panel (202) to the second side wall panel (204) of the case, form a number of layers m_(y), with m_(y) being 1 or more, arranged on top of each other from bottom to top of the case, and form a number of layers m_(z), with m_(z) being 1 or more, arranged next to each other from the front wall panel (201) to the back wall panel (203) of the case; and such that the height of each primary, flexible packages is parallel to the height of the secondary packaging and the height of the secondary packaging y_(S) is 90% to 100% of m_(y)-times the height of the average maximum height y_(P) of the number n of primary, flexible packages.
 2. The packaging assembly of claim 1, wherein the number n of primary, flexible packages is 2 or more and the number of layers m_(y) is 2 or more.
 3. The packaging assembly of claim 1, wherein at least one tertiary flexible packaging (301) covers at least partially the top opening (205) and/or the bottom opening (206) of the secondary packaging.
 4. The packaging assembly of claim 3, wherein the at least one tertiary flexible packaging (301) covers at least partially two or more of the panels selected from the front wall panel (201), the back wall panel (203), the first and the second side wall panel (202, 204) of the secondary packaging.
 5. The packaging assembly of claim 3, wherein the at least one tertiary flexible packaging (301) covers the top opening and the bottom opening of a stack of two or more secondary packaging arranged on top of each other in such a way that the top opening area of one secondary packaging is to at least 90% covered by the bottom opening area of the neighboring secondary packaging.
 6. The packaging assembly of claim 3, wherein the at least one tertiary flexible packaging (301) is a film.
 7. The packaging assembly of claim 1, wherein the secondary packaging is of generally rectangular shape.
 8. The packaging assembly of claim 1, wherein the front wall panel (201) and the back wall panel (203) and/or the first and the second side wall panel (202, 204) of the at least one case have the same size and shape.
 9. The packaging assembly of claim 1, wherein the front wall panel (201), the back wall panel (203), the first and the second side wall panel (203, 204) comprise cardboard and/or corrugated cardboard.
 10. The packaging assembly of claim 1, wherein the compressed absorbent articles (10) each comprise a front end edge (18) and the primary, flexible packages are arranged within the secondary packaging such that the front end edge (18) of each compressed absorbent article (10) points to the top opening (205) or the bottom opening (206).
 11. The packaging assembly of claim 1, wherein the compressed absorbent articles (10) each comprise a first side edge (22) and the primary, flexible packages are arranged within the secondary packaging such that the first side edge (22) of each compressed absorbent article (10) points to the top opening (205) or the bottom opening (206).
 12. The packaging assembly of claim 10, wherein the compressed absorbent articles (10) are folded along or parallel to the central lateral axis (12) such that the backsheet faces outwards.
 13. The packaging assembly of claim 1, wherein each primary, flexible package comprises at least one handle or grip (31) and is arranged such that at least one part of the at least one handle or grip (31) faces the top opening and can be gripped through the top opening (205) of the secondary packaging.
 14. A stack of two or more packaging assemblies according to claim 1 aligned on top of each other in such a way that the top opening (205) area of one assembly is to at least 90% covered by the bottom opening (206) area of the neighboring assembly.
 15. A method to assemble packaging comprising the steps of: 1) providing a number n of primary, flexible packages with n being 1 or more, wherein each primary, flexible package comprises a plurality of compressed absorbent articles, each primary, flexible package has a maximum height y′_(Pn), a maximum width x′_(Pn) and a maximum depth z′_(Pn) determined before arranging in a packaging assembly, and wherein the number n of primary, flexible packages has an average maximum height y′_(P), an average maximum width x′_(P) and an average maximum depth z′_(P) determined before arranging in a packaging assembly; 2) arranging the number n of primary, flexible packages within a secondary packaging comprising a case comprising: a front wall panel (201) and a back wall panel (203), a first and a second side wall panel, (202, 204), a top opening (205) and a bottom opening (206), and having a height y_(S), an inner width x_(S) and an inner depth z_(S); to form a number of layers m_(x), with m_(x) being 1 or more, arranged next to each other from the first (202) to the second side wall panel (204) of the case, to form a number of layers m_(y), with m_(y) being 1 or more, arranged on top of each other from the bottom to top of the case, and to form a number of layers m_(z), with m_(z) being 1 or more, arranged next to each other from the front wall panel (201) to the back wall panel of the case; such that the height of each primary, flexible packages is parallel to the height of the secondary packaging and the height of the secondary packaging y_(S) is 90% to 100% of m_(y)-times the height of the average maximum height y′_(P) of the number n of primary, flexible packages; and 3) optionally compressing the arranged primary, flexible packages such that the height of m_(y)-times the height of the average maximum height y′_(P) of the number n of primary, flexible packages is reduced.
 16. The method of claim 15, wherein the method comprises the step of applying at least one tertiary flexible packaging (301) covering at least partially two of the panels selected from the front wall panel (201), the back wall panel (203), the first and the second side wall panel (202, 204) of the secondary packaging. 